Sorting Recycled Materials With Automatically Adjustable Separator Using Upstream Feedback

ABSTRACT

Methods and systems are provided for controlling an automatic separator apparatus of a Materials Recovery Facility. The separator apparatus has a plurality of adjustable machine operating parameters. An input stream of recycled materials is provided, wherein the composition of the input stream is subject to variation during a time interval. Historical data is provided representative of a set of historical values of the operating parameters corresponding to improved quality of separation for given values of a characteristic of the input stream. A present value of the characteristic of the input stream is sensed. A plurality of machine operating parameters is automatically adjusted in response to the sensed present value of the characteristic.

This application is a divisional application of U.S. patent applicationSer. No. 11/194,708, filed Aug. 1, 2005, entitled “Sorting RecycledMaterials With Automatically Adjustable Separator Using UpstreamFeedback”, which parent application claims benefit of U.S. ProvisionalPatent Application No. 60/600,206, filed Aug. 10, 2004, entitled“Materials Recovery Facility Process Optimization Via Unit OperationFeedback”, the details of both of which are incorporated herein byreference.

This is a Utility Patent Application filed by Garry R. Kenny, a citizenof the United States, residing in West Linn, OR 97068, in an inventionentitled “Sorting Recycled Materials With Automatically AdjustableSeparator Using Upstream Feedback”

BACKGROUND OF THE INVENTION

1. Field of the Invention

The present invention relates generally to the field of sorting ofrecycled materials, and more particularly, but not by way of limitation,to methods and apparatus for optimizing the operation of an adjustablesorting apparatus or sorting system.

2. Description of Prior Art

Materials Recovery Facilities (MRFs) have been receiving and processingrecyclable materials for the past 25 years. The recyclable materialnormally consists of newspaper, plastic bottles, steel and aluminumcans, and sometimes glass bottles and fragments. The newspaper streamwas typically kept separate from the containers. During the first fiveto ten years the processing typically involved conveying the recyclablesunder a magnet to remove the steel, then past an air stream to separatethe plastic and aluminum cans from the glass bottles. The rest of thecomponents were then sorting manually by hand.

In the mid 1980s eddy current separators were introduced toautomatically remove the aluminum from the plastic bottle and aluminumcan stream. Then in the mid 1990s separation modules became available toseparate the plastic bottles by resin type and by color. Theseseparators did not, however, begin use in MRFs until around 1998. Atabout the same time the first system to automatically sort office paperwas introduced by the assignee of the present invention (MSS, Inc.) incollaboration with Weyerhaeuser Company. An example of those systems isseen in U.S. Pat. No. 6,250,472 to Grubbs et al., assigned to assigneeof the present invention and the details of which are incorporatedherein by reference.

Mechanical screens saw limited use in MRFs until the late 1990s when thefirst cardboard screens were introduced. These screens were used toremove oversize cardboard from the newspaper stream. With theintroduction of so called “single stream” collection in the late 1990s,however, screen technology was improved to address sorting of containers(i.e. plastic and glass bottles and metal cans) from the mixed paper andcardboard stream.

The first generation of screens involved either one or two flat bedscreen “decks” which were inclined in the direction of motion of thematerial. The screens themselves were comprised of a number of discsattached to rotating shafts. In operation, the more 3 dimensionalmaterials such as containers would tend to roll or bounce down thescreen deck while more 2 dimensional materials such as newspaper andcardboard would go up and over the top of the screen. An example ofinclined flat bed rotary disc screens is seen in U.S. Pat. No. 6,250,472to Grubbs et al.

This screen technology evolved to where the angle of the screen, as wellas the rotor speed, was adjustable to compensate for differing materialcomposition and moisture content. The latest generation screen patentedby CP Manufacturing is in the shape of a wide bottom V, with the entireV bottom tilted from horizontal. This screen has additional adjustablesettings with include not only the rotor speed and tilt angle of the Vsides, but also the tilt angle of the entire V. In this screen the paperis propelled by the discs up and over each side of the V. The containersroll back from the sides of the V and migrate down the bottom of the Vin the direction of the tilt. Examples of such V shape rotary discseparators are seen in U.S. Pat. No. 6,460,706 to Davis and U.S. Pat.No. 6,648,145 to Davis et al., the details of which are incorporatedherein by reference.

Unfortunately, however, very few MRF operators are capable ofdetermining the optimum operating parameters for these new screens.Experience in MRFs also shows that even when the screens are properlyset for a certain mixture of recyclables and moisture content, thatsetting is only good for a matter of a few minutes as the compositionand moisture content changes.

FIG. 1 schematically illustrates the flow of material through a typicalprior art Materials Recovery Facility (MRF) generally designated by thenumeral 10. An input waste material stream 12 enters the MRF 10. Asindicated at block 14 oversized and non-recyclable objects are removedby hand.

As indicated at block 16 a screening device may be used to separatelarge cardboard items which go to a cardboard destination 18. The bulkof the material which is made up typically of containers of varioustypes and newspaper goes to a mechanical screening device 20 whichseparates the newspaper from the containers. The mechanical screeningdevice 20 may for example be an adjustable angle trough-shaped screensuch as those shown for example in U.S. Pat. Nos. 6,648,145 and6,460,706.

The screening device 20 separates the material stream into a firststream or paper stream 22 which includes some containers, and a secondstream or container stream 24 which includes some paper.

Typically the paper stream 22 is hand sorted as indicated at block 25into a container destination 26, a paper destination 28, a contaminantdestination 30, and with ferrous and aluminum materials directed todestinations 34 and 44, respectively.

The container stream 24 from separator 20 then passes through a magneticseparator 32 which removes ferrous items into a ferrous metal stream 34.The container stream continues at 36 to a hand sorting location 38 wherenewspaper is removed at 40 and returned to the newspaper destination 28,and the containers are hand sorted into plastic containers which go todestination 42 and aluminum containers which go to destination 44.

The plastic containers at destination 42 are then again hand sorted asindicated by block 46 into PET (Polyethylene Terephalate) containers todestination 48, colored HDPE (High Density Polyethylene) to destination50, and natural HDPE (High Density Polyethylene) to destination 52.

What is needed then is a way to optimize the screen parameter settingsand to modify those settings in real time as the composition andmoisture content of the feedstream changes continuously. Even when setoptimally the screens are not 100% effective. Containers (particularlyflat ones) are sometimes carried over with the paper fraction, and aswell some paper is carried along with the containers.

What is also needed is a way to optimize all of or a portion of aMaterials Recovery Facility which includes one or more adjustablescreens.

SUMMARY OF THE INVENTION

In one embodiment the invention provides a method of separating an inputwaste material stream. The method includes measuring at least onecharacteristic of the input waste material stream correlating to adensity of the input waste material stream. An initial value is selectedfor an adjustable parameter of an adjustable material separator basedupon the at least one characteristic measured. The input waste materialstream is separated with the adjustable material separator into a firstoutput stream containing a majority of a first material and some of asecond material, and a second output stream containing a majority of thesecond material and some of the first material.

In another embodiment the present invention provides a method of sortingrecycled materials, comprising:

(a) providing an input stream of recycled materials, wherein acomposition of the input stream is subject to variation during a timeinterval;

(b) moving the input stream through a separator machine having aplurality of adjustable machine operating parameters;

(c) providing stored historical data representative of a set ofhistorical values of the operating parameters corresponding to improvedquality of separation for given values of a characteristic of said inputstream;

(d) sensing a present value of said characteristic of said input stream;and

(e) adjusting said plurality of adjustable machine operating parameters,via a computerized control system, in response to said sensed presentvalue of said characteristic of said input stream so that saidadjustable machine operating parameters approach said historical valuesof the adjustable machine operating parameters corresponding to improvedquality of separation for said sensed present value of saidcharacteristic of said input stream.

In another embodiment the invention provides an automated separatorapparatus for separating an input material stream into first and secondoutput streams, including a plurality of spaced rotating discs defininga screen having a length, a first actuator for adjusting an angle ofinclination of said length, a second actuator for adjusting a rotationalspeed of said rotating discs, a sensing unit for sensing at least onecharacteristic of said input material stream, and a control systemresponsive to said sensing unit and operably connected to saidactuators, so that said screen automatically adjusts to changes in thesensed characteristic of said input material stream.

Accordingly, it is an object of the present invention to provide methodsof adjusting the operation of an adjustable separator, using upstreamfeedback.

Another object of the present invention to provide improved methods ofadjusting the operation of an adjustable separator based upon thedensity of an incoming material stream.

And another object of the present invention is to provide methods ofautomated control of adjustable separators.

Still another object of the present invention is the provision ofmethods and systems for continuously monitoring and adjusting theoperation of a material separator to improve the efficiency of operationof the separator.

Other and further objects, features and advantages of the presentinvention will be readily apparent to those skilled in the art upon areading of the following disclosure when taken in conjunction with theaccompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart of a typical prior art Materials RecoveryFacility.

FIG. 2 is a schematic flow chart of the Materials Recovery Facility ofthe present invention utilizing automated sorting devices, and utilizingsensors and counting technology for automating the control of thesorting devices.

FIG. 3 is a schematic vertical elevation view of a trough shape rotarydisc screening apparatus.

FIG. 4 is a plan view of the apparatus of FIG. 3.

FIG. 5 is a view similar to FIG. 3 illustrating the mechanism foradjusting the V angle of the separator of FIGS. 3 and 4.

FIG. 6 is a schematic side elevation view of the apparatus of FIGS. 3-5showing the manner of adjustment of the inclination along the length ofthe trough.

FIG. 7 is a schematic side elevation view of an alternative separatorsystem including two inclined flat bed rotary disc screening devices.

FIG. 8 is a schematic illustration of the computerized control system.

FIG. 9 is a graphical representation of separating efficiency versusthroughput or feed rate for a mechanical or automated separator.

FIG. 10 is a graphical representation of the operating cost ofmechanical equipment as a function of time of operation.

FIG. 11 is a first graphical representation of manual labor costs versustime of operation where labor is available on an hourly basis.

FIG. 12 is a graphical representation of manual labor costs versus timeof operation when labor is only available in larger increments due toshift work requirements.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS The Overall MRF System

Referring now to FIG. 2, the Materials Recovery Facility (MRF) of thepresent invention is shown and generally designated by the numeral 200.FIG. 2 schematically illustrates the major components of and thematerial flow through the Materials Recovery Facility 200.

An input waste material stream 202 enters the MRF 200. As indicated atblock 204, oversized and non-recyclable objects are removed by hand.

A weight and profile sensor 206 and a moisture sensor 208 are providedto monitor the weight, the height profile and the moisture content ofthe input material stream 202.

As indicated at block 210 a large article screening device 210 may beused to separate large cardboard items which go to a cardboarddestination 212.

The bulk of the material which is typically made up of containers ofvarious types and newspaper goes to a mechanical screening device 214which may, for example, be an adjustable angle trough shape screeningdevice such as that further described below with regard to FIGS. 3-6.Alternatively the screening device may include inclined flat bed screenslike those described below with regard to FIG. 7 or other suitablescreening devices.

The screening device 214 separates the material stream into a firststream or paper stream 216 which includes some containers, and a secondstream or container stream 218 which includes some paper.

As further described below, the weight and profile sensors 206 andmoisture sensor 208 will be used to provide, among other things, aninitial estimation of the composition of the incoming material stream202 for the initial setting of operating parameters on the adjustablescreening device 214.

The paper stream 216 is carried to a first sorting module 220, which mayfor example be a FiberSort™ module, available from Advanced SortingTechnologies of Nashville, Tennessee. The first sorting module 220separates the paper stream 216 into a newspaper stream 222, a secondarycontainer stream 224 and a contaminant stream 226. The contaminantstream 226 from first separator 220 may include cardboard, six packcarriers, pizza boxes, frozen food boxes and the like.

The first sorting module 220 has associated therewith a first sensingdevice 228 which counts the number of items of various types flowinginto the newspaper stream 222, the secondary container stream 224 andthe contaminant stream 226. As is further disclosed below, this countingis preferably done on the basis of area so that what is actually countedis the area occupied by the various streams on a conveyor as they passthrough the first sorting module 220. As further described below, thedata collected from the first sensing device 228 and other sensingdevices to be described below, is utilized with an automated controlsystem (see FIG. 8) to adjust various operating parameters of theautomated equipment and to adjust flow rates for various portions of theMRF in order to optimize the operation of the MRF as desired ornecessary.

The container stream 218 exiting the separator apparatus 214 passesthrough a magnetic separator 230 which removes ferrous items into aferrous metal stream 232. The container stream 218 then flows to asecond sorting module 234. The second sorting module 234 may also be aFiberSort™ module from Advanced Sorting Technologies, similar to thefirst sorting module 220 described above. The second sorting module 234separates the container stream 218 into a plastic container stream 236,an aluminum container stream 238 and a secondary newspaper stream 240.

The second sorting module 234 has a second sensing device 242 associatedtherewith which counts the plastic containers, aluminum containers andnewspaper sorted by the second sorting module 234. Again, this countingis preferably done on the basis of the area of the conveyor belt orother conveyor mechanism passing through sorting module 234 which isoccupied by the various materials.

The supplemental newspaper stream 240 is returned to and joined with themain newspaper stream 222 exiting first sorting module 220. Similarly,the secondary container stream 224 existing first sorting module 220 isreturned to the container stream 218 upstream of magnetic separator 230.

The plastic container stream 236 passes to a third sorting module 244.The third sorting module 244 may for example be an Aladdin™ or Sapphire™sorting module, each available from MSS, Inc., which provide sorting ofdifferent types of plastic containers. Sorting module 244 sorts theplastic container stream 236 into a PET (Polyethylene Terephalate)container stream 246, a colored HDPE (High Density Polyethylene) stream248, and a natural HDPE (High Density Polyethylene) stream 250.

Third sorting module 244 has a third sensing device 252 associatedtherewith for sensing and counting the number of containers in the PETstream 246, the colored HDPE stream 248, and the natural HDPE stream250.

The sensor systems used in each of the sorting modules described abovesuch as the Aladdin™, Sapphire™ or FiberSort™ sorting modules availablefrom MSS, Inc., divide the area on the conveyor belt into an array ofpixels. Each pixel is scanned by the sensor to determine variousmeasurable characteristics of the material located in that pixel. Thedata representative of each scanned pixel is then compared to a set ofdata maps and either matches one of the known data maps or is determinedto be an unknown material, or is determined not to be an object at all.For example, the maps may be representative of metal, plastic, paper orother material. Thus each pixel, and accordingly each increment of areaon the conveyor belt passing below the sensor, is identified as eitherbeing: (1) metal, (2) plastic, (3) paper, or (4) other. Periodically thecontrol system 300 described below with regard to FIG. 8 will query thesensor units and the units will send the count total for the number ofpixels falling in each category to the microprocessor 304, and thenreset the counts to zero. Alternatively, the unit could calculate amoving average of each count type over some period (such as one minute)and then report those values directly to the microprocessor 304 whenasked. The microprocessor 304 will use the four count totals or averagesto calculate the percentage of each material in the feedstream and thetotal feed rate, if desired. This pixel count is representative of thearea that each of the identified material types occupies on theconveyor. This information will then be used to optimize the feedsystem.

The V Shape Rotary Disc Screen

One preferred separator apparatus for use as the separator apparatus 214of FIG. 1 is the adjustable V shape trough type rotary disc screenavailable from CP Manufacturing previously noted. Such an adjustablescreening device is schematically illustrated in FIGS. 3-6 and referredto by the numeral 214A. The V trough style separator apparatus 214A ispreferably constructed in accordance with the teachings of U.S. Pat. No.6,648,145 to Davis et al., the details of which are incorporated hereinby reference.

The separator apparatus 214A is in the form of a trough-shaped discscreen 112 equipped with a pair of separator air manifolds 114 and 116.Referring to FIGS. 3 and 4, the recycling apparatus 214A includes aframe 118 that rotatably supports a plurality of laterally extendingshafts 119 that spin about laterally extending axes such as 120. Theshafts 119 of the trough-shaped disc screen 112 are longitudinallyspaced and are located at progressive heights to provide a generallyV-shaped configuration as best seen in FIG. 3. The shaft that rotatesabout the axis 120 (FIG. 4) and the additional shafts to the left ofaxis 120 are rotated by a motor 122 through a drive linkage 124 in acounter-clockwise direction in FIG. 3. The shafts to the right of theaxis 120 (FIG. 4) are rotated by another motor 126 (FIG. 3) via a drivelinkage 128 to rotate the discs 129 on these shafts in a clockwisedirection in FIG. 3. The drive linkages 124 and 128 preferably eachinclude a plurality of sprockets (not illustrated) which are mounted tothe ends of the shafts 119 and a plurality of separate chains (notillustrated) entrained about these sprockets. Sprockets (notillustrated) are also mounted on separate gear reduction assemblies (notillustrated) driven by each of the motors 122 and 126. The shafts 119could be driven directly or indirectly with gears, belts, chain drives,transmissions, electric motors, hydraulic motors, internal combustionengines, and various combinations of these drive means.

The input stream 12 of mixed recyclable materials is carried by aconveyor 130 (FIG. 3) and deposited onto a lowermost region 131 of thetrough-shaped disc screen 112. While the discs 129 are referred to as“discs” they preferably have an irregular outer contour or shape so thatwhen all of the shafts 119 of the recycling apparatus 214A are rotated,mixed recyclable materials deposited thereon will be agitated and movedalong in various conveying directions. In accordance with well knowntechniques, the spacing of the discs 129 and the resulting dimensions ofthe openings therebetween determines the size of the materials that willfall downwardly between the discs 129.

The shafts of the lowermost region 131 are preferably slightlydownwardly angled from the horizontal, at an angle, for example, ofabout five degrees. The spacing of the discs 129 along the variousshafts of the trough-shaped disc screen 112 and the angle of verticalinclination of the two vertically inclined regions 112A and 112B of thedisc screen 112, along with the rotational speed of these discs, isadjustable as further described below.

Optimum classification by the recycling apparatus 110 is enhanced by theair manifolds 114 and 116 which are connected to squirrel cage blowers132 and 134 (FIG. 4). The manifolds 114 and 116 may be formed ofsegments of plastic or metal pipe with holes bored therein at intervalsto form nozzles that eject streams of air toward the discs 129 to pressnewspaper against the discs and aid in the discs 129 conveying the sameupwardly. Preferably the streams of air are inclined to help advance thenewspaper upwardly. Each of the air manifolds 114 and 116 includes aplurality of laterally extending and longitudinally spaced conduits eachhaving a plurality of laterally spaced nozzles. The conduits are coupledto a longitudinally extending header, the headers being connected torespective ones of the blowers 132 and 134. These conduits arepositioned sufficiently close to the first and second verticallyinclined regions 112A and 112B so that containers that are partiallyconveyed upwardly along the first and second vertically inclined regions112A and 112B can tumble over the first and second air manifolds 114 and116. Other sources of pressurized air besides the squirrel cage blowers132 and 134 may be utilized, such as fans, pumps, pressurized tanks, andso forth.

The lateral spacing between the discs 129 of the lowermost region 131 isless than the lateral spacing between the discs 129 of the verticallyinclined regions 112A and 112B. Broken glass falls downwardly betweenthe discs 129 of the lowermost region 131 of the trough-shaped discscreen 112. Mixed recyclable materials fall through the discs 129located along the intermediate portions of the vertically inclinedregions 112A and 112B. Newspaper is conveyed upwardly over the outputends at the upper terminal ends of the vertically inclined regions 112Aand 112B to the newspaper stream 222. Large articles such as plasticmilk bottles and soda pop containers tumble down the vertically inclinedregions 112A and 112B of the V-shaped disc screen 112 and eventuallyfall off of the side of the recycling apparatus 214A to the containerstream 224. Preferably the axes of the shafts 119 of the inclined region112A all extend in a first common plane and the axes of the shafts ofthe inclined region 112B all extend in a second common plane.

Thus a stream of mixed recyclable materials is conveyed onto one side ofthe V-shaped disc screen 112 by the conveyor 130 at the end marked“INFEED” in FIG. 4 and large articles are conveyed out of the other sideof the V-shaped disc screen 112 at the side marked “CONTAINERS OUT” inFIG. 4.

FIG. 5 is a view similar to FIG. 3 but illustrating the structure andmanner of adjustment of the V angle of the separator apparatus 214A ofFIG. 3. The inclined portions 112A and 112B are pivotally mounted to abase frame portion 136 via pivot assemblies 138 and 140. The pivotassemblies 138 and 140 comprise selected ones of the shafts 119 thatsupport the discs 129. Lifting devices in the form of hydrauliccylinders 142 and 144 are provided for independently varying the angleof inclination 146 of the inclined sections 112A and 112B to adjust andoptimize the separation of mixed recyclable materials. The liftingdevices 142 and 144 can be any other conventional lifting devices suchas motorized jack screws, pneumatic lifters, and equivalent mechanicalmechanisms used in heavy machinery to lift and move large frame members.

The articulating V shape disc screen apparatus 214A of FIG. 5 alsoincorporates internal air ducting 148 and 150 which feeds air manifolds152 to provide air jets 154 blowing onto the face of the inclined screenportions 112A and 112B to aid in holding newspaper against the inclinedportions.

As schematically illustrated in the side elevation view of FIG. 6, thebase frame 136 of the separator apparatus 214A is also inclined alongits length 156, which is generally parallel to the axis 120 of FIG. 4.An angle of inclination 158 along the length 156 is adjustable by alifting means 160 which pivots the frame 136 about a pivot point 162.The lifting means 160 may be a hydraulic cylinder or any of the othersuitable lifting means described above with regard to lifting means 142and 144.

Inclined Flat Bed Screens

Referring now to FIG. 7, an alternative separator apparatus 214Bincludes a pair of inclined flat bed screens 164 and 166. The flat bedscreens 164 and 166 may, for example, be constructed in accordance withthe teachings of U.S. Pat. No. 6,250,472 to Grubbs et al. with referenceto FIGS. 8 and 9 thereof, the details of which are incorporated hereinby reference. The inclined flat bed screens 164 and 166 may also beconstructed in accordance with the teachings of U.S. Pat. No. 6,460,706to Davis, with reference to FIGS. 1-3 thereof, the details of which areincorporated herein by reference.

Each of the flat bed screens such as screen 164 includes a plurality ofshafts such as 168 seen in end view in FIG. 7, having discs such as 170rotatable with the shaft 168. The shafts 168 are mounted upon a frame172 which is pivotable about a pivot point 174 due to lifting mechanism176 to adjust an angle of inclination 178. The shafts 168 and disc 170are rotated by a motor 180 which drives the shafts through chain 182 orother suitable linkage.

An air manifold 184 has air provided from air supply 186 so that jets188 are directed onto the face of the flat bed screen 164.

The second flatbed screen 166 is similarly constructed.

Controls Based Upon Monitoring Characteristics Of Input Stream

One approach to determining the composition of the feedstream 12 is tomeasure the weight and depth profile of the material on the conveyorthat feeds the screen with sensor 206. The density of the feed materialcan then be computed from the weight and depth profile and an estimatemade of the composition of the material entering the screens 210 and214. An approximate correlation between the density of the feedstreamand its composition can be determined by taking samples of thefeedstream over time and analyzing their composition as compared to themeasured density.

This approach can provide a first approximation to optimizing the screenoperating parameters in real time. Detailed observation of the operationof the screen and experimentation with the operating parameters withfeed material of differing densities would be used to develop a table ofoptimum operating parameters for the different feed material densities.Then as the feed material density changes the operating parameters ofthe screen would be automatically changed via variable frequency drivesfor the shaft motors and hydraulic or actuator controls for the screenangle.

The above method while approximate would still provide an improvementover current operating practices wherein the screen parameters are onlyoccasionally adjusted manually using only the operator's estimate of thefeed material composition.

Using the information from the weight and profile sensors 206 on theinfeed belt an approximate correlation can be made between the densityof the infeed and the optimum screen parameter settings. Thisinformation can also be used to determine the approximate optimum screenparameters and shorten the time for the optimization program to find theactual optimum settings.

The moisture content of the feedstream strongly effects the operation ofthe screens. The moisture is primarily contained in the paper, andalters the infrared signature of the paper depending upon the amount ofmoisture in the paper; the amount of moisture can be measured in thisway. Also devices are available for measuring the moisture content ofthe air in proximity to the paper. By adding a moisture sensor 208 tothe system, a further data point is available for “presetting” thescreen parameters based on the “setup” data collection process.

Adjustment Based Upon Measuring The Effectiveness Of The Separation

Another more accurate approach to the above problem is also possiblenow. In the past few years automated sorting devices such as sortingmodules 220, 234 and 244 have become available for MRFs. This equipmentuses near infrared spectrometer technology to identify and separateplastic bottles by resin type and to distinguish fiber (paper) objectsfrom plastic. Other equipment is available which uses eddy currenttechnology to identify metal type (e.g. ferrous versus nonferrous suchas aluminum).

By incorporating additional software into these systems, the sortingmodules can also be used to count the number of plastic, metal and paperobjects that pass through them as indicated at 228, 242 and 252 in FIG.2. What is proposed then is a system wherein data are taken from atleast two sorting modules and used to optimize the screen operatingparameters.

One sorting module 220 would receive the paper output stream 216 fromthe screen 214 while the other sorting module 234 would receive thecontainer output stream 218 from the screen 214. The first sortingmodule 220 would reclaim the containers lost to the paper stream whileat the same time counting the number of containers and paper objects viasensor 228. The second sorting module 234 would reclaim the paper lostto the container stream 218 while also counting, via sensor 242, thenumber of paper objects reclaimed and the number of containers passingthrough the sensor 242.

This information can then be used to optimize the screen parameters withthe following as an example. Other approaches to implementing thesoftware algorithm can also be implemented. It should also be understoodthat it is relatively straightforward to determine the practicaloperating range of the screen parameters by visual observation of theoperation of the screen 214. For example the angle between the sides112A and 112B on the V screen typically ranges from about 35 to 50degrees, the tilt angle 158 of the V typically ranges from about 5 to 12degrees, and the rotor motor variable frequency drive frequencytypically ranges from about 40 to 70 Hertz.

Data from sorting modules 220 and 234 would be recorded for some periodof time (from say 1 minute to 5 or 10 minutes). Then the number of paperand plastic objects counted by each module would be averaged over thatperiod of time. Then either the screen angle or rotor speed or tiltangle would be changed by a few percent (say 5 percent of the totalrange of change available). Then the data from the two sorting moduleswould be averaged over a same period of time and the results comparedwith the previous result.

If the comparison shows an improvement (reduced total paper in thecontainers and containers in the paper) then the parameter would bechanged by a few percent further in the same direction (increased ordecreased). This process would be continued until a decrease in screenperformance was found.

If the parameter change produces a decrease in screen performance thenthe change would be reversed and a few percent change made in theparameter in the opposite direction. If no change in performance ismeasured after the parameter change, then the selected parameter wouldbe sequentially changed in addition incremental percents until a changeis measured.

The actual software process would be equivalent to making a series ofoperation measurements for different settings of the selected parameter,plotting the operational efficiency again the parameter setting and thenfinding the maximum of the operation efficiency.

When the optimum setting has been determined for the selected parameter,the next parameter (e.g. rotor speed) would be changed as above whileoperating measurements are made. After all the operating parametermaximums are determined, the process is started over again. A body ofoperational data will then be collected such that each of the operatingparameters maximums are found with different values of the otherparameter settings. That is, it may be that parameter 1 could have adifferent maximum operating setting when parameter 2 is set differentlythan when the maximum for parameter 1 was determined for the firstparameter 2 setting.

The data collected above can then be stored in 3 dimensional look uptables (tilt angle axis, rotor speed, and V angle) or as concentrationsof optimum points in a 3 dimensional graph for each range of feedmaterial composition. The composition data would be derived from theoutputs of the sensor modules.

The above can be considered to be the data collection phase of theoptimization system. It is anticipated that for each new installation ofa screen as part of an overall sorting system (or a retrofit) that thedata collection phase would be implemented for sufficient time to coverthe feed material collected from all the different locations. It is wellknown that recyclables from different neighborhoods are often ofdiffering composition of paper versus containers, glass versus aluminum,etc.

These graphs or lookup tables would then be used to determine the beststarting point setting for the screen parameters for day to dayimplementation of the optimization program. The actual running of theprogram would proceed as above with continual varying of the operatingparameters while continually measuring the paper contamination in theplastic and the plastic contamination in the paper.

A further goal of the program is to refine the starting parameters basedon the measured composition of the feedstream. The closer the initialsetting of the screen parameters are to optimum the less time it willtake to reach optimization for that particular composition. Thus, themore data available on the composition the more refined the startingparameters can be.

Newly available eddy current sorting modules for aluminum cans utilizean array of eddy current detectors spanning a sorting belt. As aluminumor steel cans cross the array their presence is detected and withappropriate timing an air jet array ejects the aluminum can away fromother cans, paper or plastic containers. The array can additionally beused to count the number of aluminum (and separately steel cans) whichpass through the module. This newly available eddy current separator canthus be used to provide additional composition data for the optimizationprogram.

Recently the eddy current array has been added to the near infraredplastic sensor array to allow reclamation of aluminum cans from thescreen's paper stream in addition to the reclamation of plastic bottles.This allows counting of all the aluminum cans in the feedstream (thosein the container stream as well as those lost to the paper stream).Further the plastic bottle stream typically needs to be separated intothe three standard types, PET (drink bottles), colored HDPE (detergentbottles) and natural HDPE (milk bottles).

This separation is accomplished with the third separator module 244.Thus, further information on the composition of the feedstream is nowavailable as these modules can also count the number of each type ofplastic bottle (as well as the color).

Two components of the recyclable stream that at this time cannot bedirectly measured are the glass bottles and the steel cans. If we,however, combine the data from the three separation modules such thatthe number and therefore the approximate weight of the paper, aluminum,and plastic in the feedstream is known, then the majority of theremaining weight is glass and ferrous metal. Since the ferrous metal istypically baled and sold on a daily basis, the approximate weight of theglass can then be calculated.

The Automated Control System

The control system of FIG. 8 is generally designated by the numeral 300.The control system 300 includes a microprocessor based controller 302which includes microprocessor 304, memory 306, a software portion 308,and an input-output device 310.

The system 300 also includes the various sensors and actuatorspreviously described and schematically illustrated in FIG. 8, along withvarious communication lines (or wireless systems) connecting the sensorsto the controller 302, and the various actuators for the mechanicalseparators along with control devices for those actuators which arecapable of converting an electronic control signal from controller 302into a physical action of the actuator.

The sensors include weight sensor 206A and profile sensor 206B whichcomprise the weight and profile sensor 206 of FIG. 2. Also included isthe moisture sensor 208 of FIG. 2, and the counting devices 228, 242 and252 associated with the first, second and third sorting modules,respectively.

The actuators include the first and second lifting mechanisms 142 and144 for controlling the V angle of the V shape separator 214A. Alsoincluded is the lifting mechanism 160 for controlling the bed tilt angleof the separator 214A. Also included are the motors 122 and 126 whichcontrol the rotor speeds for the separator 214A. Also included are theblowers 132 and 134 for controlling the air pressure directed to the airjets blowing on the faces of the separator apparatus 214A.

The microprocessor 304, in response to input signals from the varioussensors, and in accordance with the programming contained in software308, and instructions received from an operator via input-output device310, sends various control signals via control signal lines 312, 314,316 and 318.

Control signals over line 312 go to control devices 320 and 322associated with lifting mechanisms 142 and 144, respectively.

A control signal communicated over control line 314 to control device324 controls the flow of hydraulic fluid to lifting mechanism 160.

Control signals are carried over control line 316 to control devices 326and 328 to control the speed of motors 122 and 126.

Control signals over control line 328 are carried to control devices 330and 331 for controlling the speed of blowers 132 and 134 which providespressurized air to the air jets.

As will be appreciated by those skilled in the art many other types ofsensors could be used to sense various parameters of the input streamand of the various product streams, and various actuators can beutilized to control the various operating parameters of the separatingdevices.

Methods Of Sorting Recycled Materials With Automatically AdjustableSeparator Using Downstream Feedback

One method of operation of the Materials Recycling Facility 200 can bedescribed as a method of sorting recycled materials which begins withproviding the input stream 202 of recycled materials, wherein acomposition of the input stream 202 is subject to variation during atime interval. This is very common for any typical materials recyclingfacility where the makeup of the recycled materials and other inputparameters such as moisture content can vary rapidly throughout the day.

That input stream 202 is moved through a separator machine such asseparator apparatus 214A of FIGS. 3-6 or 214B of FIG. 7, whichseparating machine has a plurality of adjustable machine operatingparameters.

For the V shape separator device 214A of FIGS. 3-6, the adjustableparameters include the angle of the V between the sides 112A and 112B,the tilt angle 158 of the frame parallel to its central axis 120, thespeed of the rotors as determined by the speed of motors 122 and 126,and the flow of air to the air jets from air manifolds 114 and 116.

For the inclined flat bed separators such as separator 214B of FIG. 7,the adjustable parameters include tilt angle 178, the rotor speed asdetermined by the speed of motor 180, and the air flow to air jets 188directed against the face of the separator screen.

Typically a feedback control loop for any type of control system willsimply monitor a downstream parameter and compare that to some presettarget and then adjust the upstream adjustment in order to achieve thepredetermined target. Such a feedback system could be utilized in somecases with the present invention, but the preferred control systeminstead takes each of the adjustable machine operator parameters in turnand via the control system 302 adjusts a first one of those adjustablemachine operating parameters while monitoring with the computerizedcontrol system a quality of separation achieved by the separatormachine, so as to select a value of the first parameter that improvesthe effect of the first parameter on the monitored quality ofseparation.

After the first adjustable parameter has been optimized, the controller302 will begin adjusting a second one of the adjustable machineoperating parameters while monitoring the quality of separation achievedby the separator machine, so as to select a value of the secondparameter that improves the effect of the second parameter on themonitored quality of separation. This can be continued until the secondadjustable machine operating parameter has been optimized. This iscontinued with each of the adjustable machine operating parameters forthe separator machine in question, and then the process is repeated,returning to the first of the adjustable machine operating parametersand adjusting it to see if further optimization can be achieved.

In this manner, there is a continuous ongoing process of sequentialadjustment of each adjustable machine operating parameter whileobserving the effect of that adjustment on the quality of separation, sothat in effect a continuous adjustment of the separator machine isprovided throughout its period of operation thus accommodating changesin the input stream very quickly.

When utilizing counting devices such as counters 228, 242 and 252 as themeans of sensing the effect on the downstream product, very precisemeasures of the effect of the change in one of the machine operatingparameters can be achieved.

More particularly, this method of adjustment can be described as amethod of sorting an input waste material stream 202 including a mixtureof first and second material such as paper and containers. That inputwaste material stream 202 passes through the adjustable separator 214and is separated into a first output stream 216 which in this case is apaper stream containing the majority of the paper and some contaminantcontainers, and a second output stream 218, which in this case is thecontainer stream 218, containing the majority of the containers and somecontaminant paper.

The counting devices 228, 242 and 252 can very accurately count theamount of contaminant containers in the supplemental container stream224 which is extracted from the paper stream 216, and the amount ofcontaminating paper in the supplemental paper stream 240 which isextracted from the container stream 218.

Then, when one of the adjustable machine operating parameters ofseparator 214 is adjusted, the amount of contaminant containers insupplemental container stream 224 and the amount of contaminant paper insupplemental paper stream 240 are observed, and a signal is generatedindicative of whether the combined amount of contaminant material hasdecreased. If the total amount of contaminant material contained instreams 224 and 240 has decreased, then that first adjustable parameteris further adjusted in the same direction which is the directionindicated as being favorable to decreasing the combined amount ofcontaminant material. If, however, the first adjustment resulted in anincrease in the total amount of contaminant material in streams 224 and240, then the next adjustment of the first adjustable parameter would bein the opposite direction. The first adjustable parameter of separatormachine 214 is continuously adjusted in this manner until there is nofurther improvement or reduction in the total amount of contaminants.

The first counter 228 may also be referred to as a first detector 228for detecting an amount of container contaminants in the paper stream216. The second counter 242 may be referred to as a second detector fordetecting an amount of paper contaminants in the container stream 218.

It will be appreciated that the controller 302 may be readily programmedto either equally weight the contaminants in each of the paper streamand container stream, or to favor a reduction in contaminants in onestream at the expense of an increase in contaminants in the otherstream.

As previously noted, the sorting modules 220, 234 and 244 may beselected from a number of available models which can be obtained fromMSS, Inc., the assignee of the present invention, including for examplethe FiberSort™ model, the Aladdin™ model and the Sapphire™ model. Theseseparators can use various types of sensor systems, but in general thesesystems utilize sensors which are capable of sensing the identificationof each item in the product stream via reflection of light from theitem. Light energy of a selected type is projected onto the conveyorbelt and optical sensors detect reflected light thus enabling the sensorto identify the type of material at each location on a conveyor beltflowing past the sensor.

Typical examples of such optical sensing technology are found forexample in the following U.S. patents and applications which areassigned to the assignee of the present invention or its subsidiary AST,Inc., and the details of which are incorporated herein by reference:U.S. Pat. No. 6,570,653; U.S. Pat. No. 6,778,276; U.S. Pat. No.6,369,882; U.S. patent application Ser. No. 09/516,257, entitled“Multi-Grade Object Sorting System and Method”, filed Feb. 29, 2000;U.S. patent application Ser. No. 10/921,000, filed Aug. 18, 2004 for“Sorting System Using Narrow-Band Electromagnetic Radiation”; U.S. Pat.No. 5,318,172; U.S. Pat. No. 5,460,271; U.S. Pat. No. 5,917,585; U.S.Pat. No. 5,966,217; U.S. Pat. No. 6,137,074; U.S. Pat. No. 6,144,004;U.S. Pat. No. 6,504,124; and U.S. Pat. No. 6,497,324.

The chosen sensor technology, as previously noted, is preferablyutilized to measure the presence of the various material types on anarea basis.

Methods Of Sorting Recycled Materials With Automatically AdjustableSeparators Using Upstream Feedback

In another aspect of the present invention a method is provided forseparating the input waste material stream 202. In this method, at leastone characteristic of the input waste material stream correlating to adensity of the waste material stream is measured. Preferably both weightand a height profile of the input waste material stream are measured.The weight can be measured by sensor 206A through any suitable devicefor weighing the incoming material on a portion of an incoming conveyorbelt. The profile sensing device 206B can be a light beam or the likeacross the conveyor at various height intervals so as to determine theheight of the incoming stream of waste material. Since the width of thestream on a conveyor belt is relatively constant, by knowing the weightand height the density of the incoming waste material stream can beapproximated.

Based upon that sensed density, an initial value is selected for one ormore of the adjustable parameters of separator device 214. This initialvalue is preferably determined based upon comparison of the senseddensity to a historical database of controller 302 which correlates tothe particular input stream.

Thus by sensing characteristics of the incoming material stream andcomparing the same to a historical database, an initial setting for oneor more of the various adjustable parameters of the separator machine214 can be selected so as to quickly place the separator machine 214 ina condition relatively close to its optimum operating condition.

Then, the separator machine 214 can be run through the process ofindividually adjusting each of its adjustable parameters and monitoringthe downstream effect of that adjustment on the outgoing product streamsto further optimize the individual machine.

The initial setting of the separator machine can also be based uponmeasurements of moisture content in the incoming stream as sensed bymoisture sensor 208.

The historical database is built by taking a plurality of samples of asample waste material stream and determining both the density andcomposition of each sample, to compile the database of density versuscomposition. Thus the initial estimation of the composition of the inputwaste material stream is based upon the measured incoming density, ascompared to the historical database.

The controller 302 can collect this data over a period of time andcorrelate the content of the various product streams to the measuredparameters such as density and moisture content of the input stream, andto the optimum settings for the various adjustable parameters of theseparator machine 214 so as to further build the historical database andprovide a basis for rapid selection of the optimum settings for theadjustable operating parameters of the separator device.

Methods Of Optimization Of The Overall Materials Recovery Facility

MRFs are designed to handle a “typical” composition of recyclables suchthat each sorting step is optimally loaded but not overloaded. Inoverloaded operation, whether it be automated, mechanical or a manualsorting process, removal efficiency suffers as does product purity. AlsoMRFs typically must process all the material that is delivered each day.

Therefore, as the composition of the feedstream changes it is likelythat either one or more of the separation unit operations is beingoverloaded or that the system is being run at less than its optimumcapacity, or that it is not being run at its optimum shift length.

What is needed is a system that optimizes the system operation in termsof the three above considerations. The addition of sensor modules to theMRF can provide real time feedback as to the number of objects goingthrough the various unit operations of the system. Comparing the knowncapacity of each unit operation with the actual throughput of thatoperation allows the efficiency of that operation to be determined.

All typical MRFs weigh the incoming recyclables, and many receive alltheir material before noon. Knowing the amount of material needing to beprocessed and the capacity of the system allows the approximateprocessing time to be calculated. A relatively straightforward programcan then be implemented which takes the data in real time from the unitoperations and knowing the dollar value of each component and theapproximate feedrate versus efficiency curves for each unit operationcan calculate the optimum processing rate. Conversely if the operatingtime is fixed, the program can calculate the loss in revenue due tolower product purity or the number of manual sorters that would need tobe added to the system to maintain optimum purity.

The ultimate optimization of the Materials Recovery Facility includes anoverall assessment of each of the separator devices while taking intoconsideration other factors such as the economic value of various onesof the output material streams, the cost of operating the variousmachinery, the cost of manual labor which may be necessary to supplementthe automated machinery in certain situations, and various timeconstraints such as the number of hours the Materials Recovery Facilitycan be operated each day, and of course taking into account the totalvolume of material which must be recycled and separated during theoperating day for the facility.

Optimizing the profitability of the Materials Recovery Facility dependsupon operating the mechanical equipment at the best capacity versusefficiency while minimizing the cost of manual operations, all the whileproducing the highest possible saleable material quality.

In general, the lower the feed rate to mechanical and automated sortingequipment the higher the quality of the saleable output material (i.e.glass, ferrous material, aluminum, plastic, cardboard, and paper). It ispossible to measure the general sorting parameters of both mechanicaland automated sorters with regard to sorting efficiency versusthroughput. The specific operating parameters will depend upon otherfactors such as moisture content and percentage composition, but theseare second order effects as compared to throughput. Data representativeof the feed rate versus separating efficiency relationship for anautomatic separator apparatus will typically take the form of a curvegenerally like that of FIG. 9.

In general, but with less connection, the higher quality saleable outputmaterials will command a higher selling price. However, due to marketconditions it is often the case that higher quality does not bring ahigher selling price. Further, prices for saleable materials such asglass, paper, aluminum, cardboard and steel are readily available on aday-to-day basis.

The operating costs of mechanical and automated sorting equipment arelargely proportional to the length of time the equipment is operated,rather than on the total amount of material processed. The amount ofmaterial processed does contribute to wear on the equipment, but thedominant cost factors are electrical usage and wear due to running,whether material is being processed or not. Disc screens are somewhat ofan exception to this as material flow over the screen causes significantwear to the discs which must be periodically replaced. Cost forelectrical power and spare parts costs are also readily available on aday-to-day basis and may be entered into the system. Data representativeof the operating costs of mechanical equipment will typically take theform of a curve like that set forth in FIG. 10.

Materials Recovery Facility operating costs due to manual labor areproportional to the length of time the Materials Recovery Facility is inoperation regardless of the amount of material being processed. Manualsorters cannot be sent home and then called back in a matter of a fewhours. It is also well known from experience how much material a humansorter can on average process per hour. Again, labor costs are also wellknown on a day-to-day basis and can be input into the system. Datarepresentative of the cost of manual labor will typically take the formof a curve like that of FIG. 11 or 12. FIG. 11 is representative ofmanual labor costs which are directly variable according to the time oflabor required. FIG. 12 is representative of the situation in whichlabor can only be obtained in increments such as the length of a minimumshift for a worker of four hours, eight hours or the like.

The present invention utilizes a computer program in the softwareportion 308 into which daily material prices can be entered along withcurrent manual sorting hourly costs, the amount of material that needsto be processed that day, and in which the program can compute theoptimum processing time and/or personnel for the day's material togenerate the maximum possible net revenue. The program has operatingcharacteristics available, such as in lookup tables or in graph form,for feed rate versus separation quality, manual sorting capacity, wearcharacteristics of the various mechanical components and the like, aswell as the material pricing data noted above.

One such method of optimization can be described as a method ofcontrolling a Materials Recovery Facility. An automatic separatorapparatus is used for separating the input material stream into at leasta first output stream 216 and a second output stream 218 containingpredominantly first and second materials, in this case paper andcontainers, respectively. Data representative of a feed rate versusseparating efficiency relationship for the automatic separator apparatus214 is provided to the automatic control system 300. It will beappreciated that the faster the separator device 214 is operated, theless efficient it will typically be and the more contaminants will becontained in each of the streams 216 and 218. On the other hand, if theseparator 214 is operated too slowly it may not be possible to processall of the material that may be processed within the allotted time. Theautomatic control system 300 can calculate an optimum processing rate tomaximize the profitability of the separation process. The control systemcan then adjust the feed rate of the input material stream to theautomatic separator apparatus so that said feed rate approximates theoptimum processing rate.

The control system can provide such a calculated optimum processing ratefor the separator 214 and for the various sorting modules 220, 234 and244, each of which will have a feed rate versus separating efficiencyrelationship.

The control system will further take into account costs that arerepresentative of a cost of operating the Materials Recovery Facility.That cost data can include data representative of a cost of manual laborfor supplemental manual sorting to sort contaminants from one or more ofthe various output streams. That cost data can further includeconsideration of an increased cost of manual labor for supplementalmanual sorting needed as a result of increased feed rate to one or moreof the separators.

The software portion 308 of controller 302 includes a data inputsoftware portion for receiving data representative of such an economicvalue of a product of at least one of the product streams. The datainput software portion can also receive inputs of current costs ofoperation of various portions of the Materials Recovery Facility alongwith the current cost of manual labor for supplemental manualseparation.

It will be appreciated that the historical database can also includedata representative of the amount of supplemental manual labor that maybe necessary, for example when one or more portions of the MaterialsRecovery Facility are operated at such a high feed rate that totallyefficient separation cannot be achieved and thus manual supplementationmay be required. The data input software portion of the automaticcontrol system is also adapted to receive input of total throughputrequirement for the facility for a given time interval and a constraintfor processing the total throughput requirement through the facility.

Thus it is seen that the apparatus and methods of the present inventionreadily achieve the ends and advantages mentioned as well as thoseinherent therein. While certain preferred embodiments of the inventionhave been illustrated and described for purposes of the presentdisclosure, numerous changes in the arrangement and construction ofparts and steps may be made by those skilled in the art, which changesare encompassed within the scope and spirit of the present invention asdefined by the appended claims.

1. A method of sorting recycled materials, comprising: (a) providing aninput stream of recycled materials, wherein a composition of the inputstream is subject to variation during a time interval; (b) moving theinput stream through a separator machine having a plurality ofadjustable machine operating parameters; (c) providing stored historicaldata representative of a set of historical values of the operatingparameters corresponding to improved quality of separation for givenvalues of a characteristic of said input stream; (d) sensing a presentvalue of said characteristic of said input stream; and (e) adjustingsaid plurality of adjustable machine operating parameters, via acomputerized control system, in response to said sensed present value ofsaid characteristic of said input stream so that said adjustable machineoperating parameters approach said historical values of the adjustablemachine operating parameters corresponding to improved quality ofseparation for said sensed present value of said characteristic of saidinput stream.
 2. The method of claim 1, wherein the characteristic ofthe input stream is density.
 3. The method of claim 2, wherein thedensity of the input stream is estimated by measuring a height of aportion of said input stream and a weight of said portion of said inputstream.
 4. The method of claim 1, wherein the characteristic of theinput stream is moisture content.
 5. The method of claim 1, wherein: instep (a) the input stream is comprised primarily of paper andcontainers, the paper being primarily newspaper; and in step (b) theseparator machine separates the input stream into a paper stream made upprimarily of paper, and a container stream made up primarily ofcontainers.